Storage system

ABSTRACT

A storage system includes a first grid structure of storage cells, each cell being arranged to accommodate a vertical stack of storage bins, and the first grid structure having a top level. The system further includes a first vehicle, arranged to move horizontally at the top level of the first grid structure, and a bin lift device, arranged to convey a bin in a vertical direction between the top level of the grid structure and a delivery station. The first vehicle is further arranged to receive a storage bin from a storage cell at the top level of the first grid structure and to deliver the storage bin to the bin lift device. The bin lift device is arranged to receive a bin from the vehicle at the top level of the first grid structure and to convey the bin to the delivery station.

TECHNICAL FIELD

The present invention relates to the technical field of logistics andstorage systems.

More specifically the invention relates to a storage system whichcomprises a first grid structure of storage cells, each storage cellbeing arranged to accommodate a vertical stack of storage bins, thefirst grid structure having a top level. The system further comprises afirst vehicle, arranged to move horizontally at the top level of thefirst grid structure, and a bin lift device, arranged to convey a bin ina vertical direction between the top level of the grid structure and adelivery station. The first vehicle is further arranged to receive astorage bin from a storage cell at the top level of the first gridstructure and to deliver the storage bin to the bin lift device.Moreover, the bin lift device is arranged to receive a bin from thevehicle at the top level of the first grid structure and to convey thebin to the delivery station.

BACKGROUND

The Applicant's AutoStore system is a storage system of the typementioned in the introduction. The AutoStore system includes a threedimensional storage grid containing storage bins that are stacked on topof each other to a certain height. The storage grid is constructed asaluminium columns interconnected by top rails. A number of vehicles, orrobots, are arranged on the top rails. Each vehicle is equipped with alift for picking up, carrying, and placing bins that are stored in thestorage grid.

Such a storage system of the background art has been illustrated inFIG. 1. The storage system 10 comprises a grid structure 20 of storagecells. Each cell is arranged to accommodate a vertical stack of storagebins 30. The grid structure has a top level.

The storage system 10 further comprises a vehicle 40, which is arrangedto move at the top level of the grid structure and also arranged toreceive a bin from a storage cell at the top level of the gridstructure. The storage system 10 may include a plurality of suchvehicles 40, as illustrated.

The storage system 10 further comprises a bin lift device 50. The binlift device 50 is arranged to receive a bin from the first vehicle 40 atthe top level of the first grid structure and to convey the bin down ina vertical direction to a delivery station, or port, 60. The storagesystem 10 may include a plurality of such lift devices 50 and ports 60,as illustrated.

SUMMARY

The invention has been defined in the patent claims.

One or more embodiments of the invention provide an improved storagesystem with respect to at least one of performance, capacity,utilization of area, and flexibility. More specifically, one or moreembodiments of the invention provide a system as set forth in theintroduction, which further comprises a second grid structure of storagecells at a different vertical level than the first grid structure, and asecond vehicle that is arranged to move horizontally at the top level ofthe second grid structure. The second vehicle is further arranged toreceive a storage bin from a storage cell at the top level of the secondgrid structure and to deliver the storage bin to the bin lift device.The bin lift device is further arranged to convey a bin in a verticaldirection between the top level of the first grid structure and thesecond grid structure.

Further possible features, including exemplary aspects, structure andoperation of various embodiments, have been described in detail belowwith reference to the accompanying drawings. In the drawings, likereference numbers indicate identical or functionally similar elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, partly cut perspective view of a storage systemaccording to the background art;

FIG. 2 is a schematic, partly cut perspective view illustrating certainaspects of a storage system in accordance with embodiments disclosedherein;

FIG. 3 is a schematic side elevation illustrating certain aspects of astorage system in accordance with embodiments disclosed herein;

FIG. 4 is a schematic perspective view illustrating certain aspects of abin lift device in accordance with embodiments disclosed herein;

FIG. 5 is a schematic perspective view illustrating certain aspects of abin lift device at the top of an upper grid structure in accordance withembodiments disclosed herein;

FIG. 6 is a schematic perspective view illustrating certain aspects of abin lift device at the top of an intermediate grid structure inaccordance with embodiments disclosed herein;

FIG. 7 is a schematic perspective view illustrating certain aspects of abin lift device and a delivery station in accordance with embodimentsdisclosed herein;

FIG. 8 is a schematic perspective view illustrating certain aspects of atwin bin lift device at the top of an upper grid structure in accordancewith embodiments disclosed herein;

FIG. 9 is a schematic perspective view illustrating certain aspects of atwin bin lift device and two delivery stations in accordance withembodiments disclosed herein;

FIG. 10 is a schematic block diagram illustrating principles of networkcommunication between storage system components in accordance withembodiments disclosed herein.

DETAILED DESCRIPTION

FIG. 1 is a schematic, partly cut perspective view of a storage systemaccording to the background art, which has already been referred to inthe background section.

FIG. 2 is a schematic, partly cut perspective view illustrating certainaspects of a storage system.

The storage system includes a first, upper grid structure of storagecells, arranged on an upper floor 80. Each storage cell is arranged toaccommodate a vertical stack of storage bins. The first grid structurehas a top level 20. One or more embodiments provides an improved storagesystem with respect to at least one of performance, capacity,utilization of area, and flexibility.

A first vehicle 40 is arranged to move at the top level 20 of the uppergrid structure and arranged to receive a storage bin from a storage cellat the top level 20. A plurality of such vehicles may be arranged on thetop level 20 of the upper grid structure, as shown in FIG. 2.

At least one vertical bin lift device is arranged in the system in oneor more embodiments. One such bin lift device has been shown at 56. Itis arranged to receive a bin from the vehicle at the top level of theupper grid structure 20 and to convey the bin down in a verticaldirection to a delivery station 66, which in this example is arranged atthe ground floor in the building wherein the storage system isinstalled. The inter-grid bin lift device 56 is arranged to deliver binsto an operator at the delivery station 66 arranged on a ground floor 26.The delivery station 66 may also receive bins from the operator anddeliver them to the inter-grid bin lift device 56.

In one or more embodiments, the storage system further comprises a lowergrid structure of storage cells on a different vertical level than thefirst grid structure. In this example the lower grid structure has a toplevel 22 and is arranged below the upper grid structure. The lower gridstructure may e.g. be a main storage grid structure.

Vehicles of the kind previously described are arranged to move at thetop level of both the upper and the lower grid structure. In one or moreembodiments, each vehicle is arranged to receive a storage bin from astorage cell at the top level of the respective grid structure.

In one or more embodiments, each inter-grid bin lift device, such as theinter-grid bin lift device 56, is arranged to receive a storage bin fromthe vehicle at the top level of the upper grid structure and to conveythe storage bin in a vertical direction to the top level of the lowergrid structure. The inter-grid bin lift device 56 is further arranged toconvey the storage bin in a vertical direction to the delivery station66.

In one or more embodiments, the inter-grid bin lift device 56 is furtherarranged to receive a storage bin from the vehicle at the top level 22of the lower grid structure and to convey the storage bin in a verticaldirection to the top level 20 of the upper grid structure.

The system may also include at least one additional inter-grid bin liftdevice, which is not necessarily connected to a delivery station, andwhich is arranged to receive a storage bin from the vehicle at the toplevel of any one of the upper or lower grid structures and to convey thestorage bin in a vertical direction to the top level of any one of theupper or lower grid structures.

The system may also include any number of bin lift devices which do notextend between grids on different levels (i.e., which are not inter-gridbin lift devices), but which merely provides access from one particulargrid to a delivery station.

In one or more embodiments, such as illustrated in FIG. 2, bin liftdevices such as the bin lift device 56 are each connected to a deliverystation 66 which is arranged below the lowermost grid structure, sincethe lower grid structure is on a higher vertical level than the deliverystation 66. However, alternatively or in addition, any number of binlift devices may be connected to a delivery station which is installedon any side of the grid structures, on any grid structure level.Delivery station(s) may in certain circumstances even be located at alevel above the top of the uppermost grid structure.

When a vehicle delivers a storage bin to a bin lift, the bin liftexchanges this bin with the previously used bin and the vehicle returnsit back to storage.

The storage system may further comprise additional vehicles arranged tomove at the top level of the upper grid structure 20 and arranged toreceive a storage bin from a storage cell at the top level of the uppergrid structure.

The storage system may further comprise additional vehicles arranged tomove at the top level of the lower grid structure 22 and arranged toreceive a storage bin from a storage cell at the top level of the lowergrid structure.

Each vehicle may have two sets (pairs) of wheels that enable it to movehorizontally on rails which extend along two axes on the top of eachgrid structure 20, 22. The axes may be perpendicular. This makes itpossible for all vehicles to reach any position on the top of therelevant grid structure.

Each vehicle is equipped with a lift for picking up, carrying, andplacing storage bins that are stored in the corresponding gridstructure. The robot communicates with a control system via a wirelesslink and is automatically recharged when needed, typically at night.

The storage system may further comprise additional grid structures ofstorage cells. More particularly, the storage system may include 2, 3,4, 5 or more grid structures of storage cells, each arranged on aseparate vertical level.

The storage system may further comprise additional vehicles arranged tomove at the top level of any possible further grid structure included inthe system, e.g. a third grid structure, and arranged to receive astorage bin from a storage cell at the top level of that grid structure.

Each grid structure may, e.g. be constructed as an aluminium (or otherpossible materials) structure, organized in rectangular storage cells.Each storage cell has room for several storage bins that are stored ontop of each other. Different configurations of height and shape arepossible, making the grid structure able to surround pillars and otherobstacles.

On the top of each grid structure 20, 22 there is arranged tracks in twodimensions, allowing the vehicles assigned for this particular grid tomove.

A storage bin is the basic module in which goods are stored. The storagebin may, e.g., be embodied in two different heights and can be producedin different materials in order to achieve particular properties, suchas polypropylene or high-density polyethylene. In a particular aspect,anti-static bins may be used for accommodating electronics components.By example, a bin may have length 600 mm×width 400 mm, with heights of210 mm or 310 mm.

In an aspect, at least one of the grid structures may be a consolidationgrid. A consolidation grid is a grid used for intermediate storing,e.g., for storing a plurality of bins that contain goods intended for aparticular order.

FIG. 3 is a schematic side elevation illustrating certain aspects of astorage system.

One or more embodiments of the storage system includes a first, uppergrid structure of storage cells, arranged on an upper floor 80. Eachstorage cell is arranged to accommodate a vertical stack of storagebins. The first grid structure has a top level 20.

In one or more embodiments, a first vehicle (not shown) is arranged tomove at the top level 20 of the first grid structure and arranged toreceive a storage bin from a storage cell at the top level 20. Aplurality of such vehicles may be arranged on the top level 20 of thefirst grid structure.

At least one vertical bin lift device is arranged in the system. Onesuch bin lift device has been shown at 56, although a plurality of binlift devices may be employed. The bin lift device 56 is arranged toreceive a bin from the vehicle at the top level of the first gridstructure 20 and to convey the bin down in a vertical direction to adelivery station 66, which in this example is arranged at the groundfloor in the building wherein the storage system is installed. Theinter-grid bin lift device 56 is arranged to deliver bins to an operatorat the delivery station 66 arranged on a ground floor 26 in a building.The delivery station 66 may also receive bins from the operator anddeliver them to the inter-grid bin lift device 56.

In one or more embodiments, the storage system further comprises asecond, intermediate grid structure of storage cells on a differentvertical level than the first grid structure. In this example thesecond, intermediate grid structure has a top level 22 and is arrangedbelow the first grid structure.

In one or more embodiments, the storage system further comprises athird, lower grid structure of storage cells on a different verticallevel than the first grid structure and the second grid structure. Inthis example the third, lower grid structure has a top level 24 and isarranged below the second grid structure. The third grid structure maybe a main storage grid structure.

Vehicles of the kind previously described are arranged to move at thetop level of both the second and the third grid structure. They arearranged to receive a storage bin from a storage cell at the top levelof the respective grid structure.

In one or more embodiments, each inter-grid bin lift device, such as theinter-grid bin lift device 56, is arranged to receive a storage bin fromthe vehicle at the top level of the first grid structure and to conveythe storage bin in a vertical direction to the top level of the secondgrid structure. The inter-grid bin lift device 56 is further arranged toconvey the storage bin in a vertical direction to the delivery station66.

In one or more embodiments, the inter-grid bin lift device 56 is furtherarranged to receive a storage bin from the vehicle at the top level ofthe second grid structure and to convey the storage bin in a verticaldirection to the top level of the first grid structure.

In one or more embodiments, the inter-grid bin lift device 56 is furtherarranged to receive a storage bin from the vehicle at the top level ofany of the first, second or third grid structures and to convey thestorage bin in a vertical direction to the top level of any one of thefirst, second or third grid structures.

The system may also include at least one additional inter-grid bin liftdevice, which if not necessarily connected to a delivery station, andwhich is arranged to receive a storage bin from the vehicle at the toplevel of any one of the first, second or third grid structures and toconvey the storage bin in a vertical direction to the top level of anyone of the first, second or third grid structures.

The system may also include bin lift devices such as the bin lift device50 which do not extend between grids on different levels (i.e., notinter-grid bin lift devices), but which merely provides access from oneparticular grid to a delivery station 60.

In one or more embodiments, delivery station(s) may be installed on allsides of the grid structures, or even below the lowermost grid structureif the grid structure is on a higher vertical level than the deliverystation. The delivery station may even be located at a level above thetop of the uppermost grid structure.

When a vehicle delivers a storage bin to a bin lift, the bin liftexchanges this bin with the previously used bin and the vehicle returnsit back to storage.

The storage system may further comprise additional vehicles arranged tomove at the top level of the first grid structure 20 and arranged toreceive a storage bin from a storage cell at the top level of the firstgrid structure.

The storage system may further comprise additional vehicles arranged tomove at the top level of the second grid structure 22 and arranged toreceive a storage bin from a storage cell at the top level of the secondgrid structure.

The storage system may further comprise additional vehicles arranged tomove at the top level of any further grid structure, e.g. the third gridstructure 24, and arranged to receive a storage bin from a storage cellat the top level of that grid structure.

The storage system may further comprise additional grid structures ofstorage cells. More particularly, the storage system may include 2, 3,4, 5 or more grid structures of storage cells, each arranged on aseparate vertical level.

In one or more embodiments, each grid structure may, e.g. be constructedas an aluminium (or other possible materials) structure, organized inrectangular storage cells. Each storage cell has room for severalstorage bins that are stored on top of each other. Differentconfigurations of height and shape are possible, making the gridstructure able to surround pillars and other obstacles.

On the top of each grid structure 20, 22, 24 there is arranged tracks intwo dimensions, allowing the vehicles assigned for this particular gridto move.

In one or more embodiments a storage bin is the basic module in whichgoods are stored. The storage bin may, e.g., be embodied in twodifferent heights and can be produced in different materials in order toachieve particular properties, such as polypropylene or high-densitypolyethylene. In a particular aspect, anti-static bins may be used foraccommodating electronics components. By example, in one or moreembodiments, a bin may have length 600 mm×width 400 mm, with heights of210 mm or 310 mm.

In an aspect, at least one of the grid structures may be a consolidationgrid. A consolidation grid is a grid used for intermediate storing,e.g., for storing a plurality of bins that contain goods intended for aparticular order.

Each vehicle may have two sets of wheels that enable it to movehorizontally on rails which extend along two axes on the top of eachgrid structure 20, 22, 24. The axes may be perpendicular. This makes itpossible for all vehicles to reach any position on the top of therelevant grid structure.

Each vehicle is equipped with a lift for picking up, carrying, andplacing storage bins that are stored in the corresponding gridstructure. The robot communicates with a control system via a wirelesslink and is automatically recharged when needed, typically at night.

FIG. 4 is a schematic perspective view illustrating certain aspects of abin lift device in accordance with embodiments disclosed herein. The binlift device 50 includes a movable support for a bin 30, the movablesupport being arranged to slide in a vertical frame which includes atleast two, possibly four, vertical columns, which are arranged atcorresponding corners of the bin when positioned to be supported by themovable support. The bin lift device is further arranged to be elevatedor lowered by appropriate lifting means.

FIG. 5 is a schematic perspective view illustrating certain aspects of abin lift device 30 at the top of an upper grid structure in accordancewith embodiments disclosed herein. The upper ends of the columns of thevertical frames are interconnected by an upper framework constitutingthe upper level 20 of the grid structure. The upper framework hasopenings corresponding to the shape and size of the bin 30 that islifted and lowered by the bin lift device 50.

FIG. 6 is a schematic perspective view illustrating certain aspects of abin lift device at the top of an intermediate grid structure inaccordance with embodiments disclosed herein. The bin lift device 50 hasfeatures corresponding to those illustrated in FIG. 5, but the framework70 constitutes the upper level 22 of an intermediate grid structure.Further, two columns of the bin lift device 50 extend further upwards toanother grid structure at a higher level, e.g. the upper grid structure20.

FIG. 7 is a schematic perspective view illustrating certain aspects of abin lift device and a delivery station in accordance with embodimentsdisclosed herein. The delivery station 60, or port, is arranged at thelower end of the bin lift device 30. The delivery station 60 serves thepurpose of delivering a bin to a human operator of the system, and toreceive bins from the operator. The delivery station may be arranged,e.g., at a ground floor.

FIG. 8 is a schematic perspective view illustrating certain aspects of atwin bin lift device at the top of an upper grid structure in accordancewith embodiments disclosed herein. The twin bin lift device includes twobin lift devices 50, 52 as already described with reference to the binlift device 50 above, which may be arranged at opposite sides of apillar, or constructional supporting column, 80.

FIG. 9 is a schematic perspective view illustrating certain aspects of atwin bin lift device and two delivery stations in accordance withembodiments disclosed herein. The twin bin lift device includes two binlift devices as already described with reference to FIG. 8, and twodelivery stations 60, 62 arranged at opposite sides of the pillar, orconstructional supporting column, 80.

FIG. 10 is a schematic block diagram illustrating principles of networkcommunication between storage system components in accordance withembodiments disclosed herein.

In one or more embodiments, each of the vehicles 40, 42 may be remotelycontrolled, for instance by means of a wireless radio-basedcommunication link. To this end, an access point 110 has been providedas a wireless router for providing communication between a control unit100, e.g. a computer, and each vehicle 40, 42. The access point may bearranged in the vicinity of the system as a whole, or separate accesspoints may be employed for different parts of the storage etc.

Also, in one or more embodiments, each vehicle is provided with wirelesscommunication means configured to provide wireless communication. Eachvehicle is further provided with an electrical energy source, such as arechargeable battery, in order to supply electrical effect to a motor ora plurality of motors which are also incorporated in each vehicle.

In one or more embodiments, the control unit 100 is further operativelyconnected to control equipment controlling the delivery stations 66.

In one or more embodiments, the control unit 100 is further operativelyconnected to console equipment and viewing equipment.

In one or more embodiments, the control unit 100 includes an interfacenetwork and a customer network, which is configured, in use, to providecommunication with a database such as an SQL database and furthercomputing equipment or devices.

The detailed description has been presented above for the purpose ofunderstanding the principles of the present invention. It will beunderstood that the invention is not limited to the particularembodiments described herein. Various modifications, rearrangements andsubstitutions may readily become apparent to those skilled in the artwithout departing from the scope of the invention, which is defined bythe following claims and their equivalents.

1. A storage system, comprising a first grid structure of storage cells,each storage cell being arranged to accommodate a vertical stack ofstorage bins, the first grid structure having a top level, a firstvehicle, arranged to move horizontally at the top level of the firstgrid structure, a bin lift device, arranged to convey a bin in avertical direction between the top level of the grid structure and adelivery station, wherein the first vehicle is further arranged toreceive a storage bin from a storage cell at the top level of the firstgrid structure and to deliver the storage bin to the bin lift device,wherein the bin lift device is arranged to receive a bin from thevehicle at the top level of the first grid structure and to convey thebin to the delivery station, a second grid structure of storage cells ata different vertical level than the first grid structure, a secondvehicle, arranged to move horizontally at the top level of the secondgrid structure, wherein the second vehicle is further arranged toreceive a storage bin from a storage cell at the top level of the secondgrid structure and to deliver the storage bin to the bin lift device,wherein the bin lift device is further arranged to convey a bin in avertical direction between the top levels of the first grid structureand the second grid structure, and wherein the second grid structure isarranged below the first grid structure.
 2. The storage system accordingto claim 1, wherein the first and second grid structures are arranged onseparate floors or mezzanines in a building.
 3. The storage systemaccording to claim 1, wherein the bin lift device is arranged to receivea bin from the vehicle at the top level of the second grid structure andto convey the bin to the delivery station.
 4. The storage systemaccording to claim 3, wherein the second grid structure is arrangedbelow the first grid structure and the delivery station is arrangedbelow the level of the second grid structure.
 5. The storage systemaccording to claim 4, wherein the delivery station is arranged on theground floor in a building.
 6. The storage system according to claim 1,further comprising additional vehicles arranged to move at the top levelof the first grid structure and arranged to receive a storage bin from astorage cell at the top level of the first grid structure.
 7. Thestorage system according to claim 1, further comprising additionalvehicles arranged to move at the top level of the second grid structureand arranged to receive a storage bin from a storage cell at the toplevel of the second grid structure.
 8. The storage system according toclaim 1, further comprising at least one additional grid structure ofstorage cells, arranged on a vertical level different from the verticallevels of other grid structures in the system.
 9. The storage systemaccording to claim 8, wherein the first grid structure is an upper gridstructure and the second grid structure is an intermediate gridstructure, and wherein the at least one additional grid structuresincludes a lower grid structure.
 10. The storage system according toclaim 8, wherein at least one of the grid structures is a consolidationgrid.
 11. The storage system according to claim 1, wherein theinter-grid bin lift device is further arranged to receive a storage binfrom the vehicle at the top level of the second grid structure and toconvey the storage bin in a vertical direction to the top level of thefirst grid structure.
 12. The storage system according to claim 1,further comprising at least one additional inter-grid bin lift device,arranged to receive a storage bin from the vehicle at the top level ofthe first grid structure and to convey the storage bin in a verticaldirection to the top level of the second grid structure.
 13. The storagesystem according to claim 1, further comprising a control unit andnetwork communication devices configured to provide wirelesscommunication between the control unit and said vehicles.